Metal decking



Nov. 14, 1939. c DAVls 2,180,317-

METAL DECKING Filed May 27, 1939 16 Sheets-Sheet l ATTORNEY.

c. F. DAVIS METAL DECKING Nov. 14, 1939.

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METAL DECKING Filed May 27, 1939 16 Sheets-Sheet 9 BY Mm ATTORNEY.

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Filed May 27, 1939 16 Sheets-Sheet ll INVENTOR.

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16 Sheets-Sheet 12 Filed May 27, 1939 INVE TOR. DAV/6 ATTORNEY.

Nov. 14, 1939. c. F. DAVIS 2.180.317

METAL DECKING Filed May 27, 1939 16 Sheets-Sheet l3 ATTORNEY.

Nov. 14, 1939. c, DAws 2,180,317

METAL DECKING Filed May 27, 1939 16 Sheets-Sheet 14 1 JIN'VIE'NITC'R.

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C. F. DAVIS METAL DECKING Now 14, 1939.

16 Sheets-Sheet 16 Filed May 27, 1939 iNVENTOR. 64 42/1 5 0 4u/a @4 v ATTORNEY.

Patented Nov. 14, 1939 UNITED STATES PATENT OFFICE METAL DECKIN G Application May 27, 1939, Serial No. 276,213

20 Claims.

The present invention relates to building units and constructions involving the same, together with accessories usable therewith.

The principal object of the invention is to produce a building unit of simple construction which may be produced in quantity, which will be light in weight yet capable of sustaining workable live loads with adequate sheer resistance.

There are on the market today a large number of types of so-called metal decks. composed of steel sheets formed to shape, the individual units being designed to interengage a'neighboring unit to form an extended area. An important object of the invention resides in a construction which will be an improvement thereover, particularly in that the present improved units are stronger, lighter without sacrificing ability to withstand load and sheer, and also capable of being positively interlocked with each other so as to prevent accidental relative movement in all directions, not heretofore possible.

Another important object of the invention resides in the provision of a building system which may be used for floor or roof decks or vertical walls capable of great flexibility of application, and with which other building materials such as wood, gypsum, concrete, insulation and covering or protecting materials may readily cooperate to form an efiicient type'of construction.

Still another object of the invention includes the design of units so interengaged along longitudinal edges as to form therebetween I-beams. As a consequence of such a construction, extensive spans may be made between supports, inas- 35 much as the integral I-beam feature lends distinctive load supporting ability to such construction apart from supporting beams, girders,

purlins or the like usually thought necessary. As a matter of fact, a construction involving ,the herein described units has the ability for self support to such an extent that in arched constructions, such for instance, as in roofs or the like, spans up to several hundred feet may be accomplished without intermediate. supports, relying entirely upon-the interengagement and cooperative support between the units.

Other objects and advantages will appear as the description proceeds.

To this end, the invention contemplates in its broadest aspect a building unit of metal or the like, of hot or cold rolled sheets or cast as the case may be, depending upon the circumstances in which it is to be used. Such unit may comprise a span portion suitably strengthened or not as by use of ribs or grooves, such portion having at each of two opposite sides, preferably longitudinally, a web extending at right angles to the span portion. Each web is provided with a locking portion adapted to cooperate with a complementary portion on an adjacent unit or with 5 such web by reason of an independent and intermediate locking device to prevent accidental displacement of the units and to positively fasten the units together. Preferably this interlocking system comprises an outstanding tongue on one 19 web with a corresponding inwardly projecting groove on the opposite web so arranged that the two may interengage or interlock in a secure, spring or friction joint. In all cases, the webs are provided with angular flanges at the end 15 portions thereof substantially parallel with the span portion. Thus, the unit, has at each longitudinal edge thereof an adequate base for contact with supporting walls, beams, purlins or the like, where these are desirable. The flange terminates 20 in a strengthening edge portion which may take the form of an angularly bent rim or edge or a rolled bead or the like. As a consequence, a particularly strong construction results whichresists collapsing or bending stresses to an optimum 25 degree.

The invention also contemplates a building construction involving such units where a series of them are erected adjacent each other in an interengaging manner, either by reason of the 30 interlocking portions of the units themselves or an interlock through the instrumentality of separate devices.

Such building constructions are of remarkable rigidity and have interesting load sustaining ability by reason of the fact that the interengaging webs constitute an I-beam construction knovzn to be'eflicient from an engineering standpoin I The invention further contemplates the use of 40 splice plates or reinforcing sections located either between the webs of adjacent units or inside of an individual unit, that is, between the flange on the web and the span portion, as circumstances will dictate. Such strengthening devices may take various forms as will be more fully hereinafter described.

The invention additionally contemplates a floor or room deck of such units where a finish material will overlie the area made of the adjacent span portions, such finish material being attached to or tied into the unit construction so as to make the combination fixed and permanent.

Due to the fact that such units may be readily made from formed sheet material, they may be made of any depth desired and where there is a uniformity of dimension between the interlocking tongue and/or groove and the surface of the span, units of different depth may be readily interlocked together to forma fiush surface. This is particularly desirable in building constructions where supporting beams occur at different levels, or where it is desired to have a heavier and deeper deck area at certain locations to withstand additional loads.

Another very important aspect contemplated by the invention resides in the ability of these units to be incorporated into a building construction involving set cementitious material such as gypsum, concrete or the like. As in situations where the units are made of sheet metal, they may be readily cut, and fitted around columns, beams, Stairways or the like with facility and pieced, filled'out, reinforced or covered with poured-in-place cementitious constructions. This construction is very important from the standpoint of fioor or roof decks where large areas may be quickly laid down and thereafter the desired openings marked out and the necessary sections of the deck removed to form the desired openings.

Another important consideration of units of the present type made from sheet metal is that they may be readily cut or split longitudinally and therefore telescopically collapsed both longitudinally or laterally to make narrower or shorter units as the case may be. This enables the user to fill out a floor or roof construction to the edge and if perchance the area to be covered will not take a whole unit, one may be cut down to the desired size without sacrifice of the I-beam feature.

In constructions involving long spans, the invention contemplates the production of units having one or more series of tongues and grooves or interlocking portions arranged at equal or unequal distances along the web. As a consequence, a single span may involve a plurality of types of units, each of which have a different number of interlocking portions, preferably, however, arranged so that these interlocks may be engaged serially. Such a construction enables a flush surface to be obtained and either the flat or curved type even though different depths of units are involved.

The flexibility of application of the units herein described will be appreciated from the fact that they may be used with the span portion either constituting the top or bottom of the building construction. In the latter case, the webs and their flanges project upwardly from the span portion and form what may be termed a. standing seam deck, the seam being constituted by the adjacent flanges on the ends of the webs.

The invention further contemplates the novel combination, construction and arrangement of units and their accessories more fully hereinafter described and shown in the accompanying drawings.

In the drawings, which are illustrative of preferred forms only,-

Fig. 1 is a perspective view of a unit embodying my invention;

Fig. 2 is a fragmentary sectional view of interlocked units showing a modified form of interconnection;

Fig. 3 is a sectional elevation along the line 3-3 of Figs. 1 and 2;

Fig. 4 is a sectional elevation s ow ng arsaarr slightly modified form of strengthening rib over that of Fig. 3;

Fig. 5 is a fragmentary sectional end view of a unit having a modified form of strengthening bead at the end of the flange;

Fig. 6 is a composite perspective view showing the method of assembly of a plurality of units both endwise and laterally with strengtheni joint members and finish attached clips;

Fig. '7 is a perspective view of a modified form of joint splice plate;

Fig. 8 is a similar view of a modified form of finishing clip; Fig. 9 is a. perspective underside view of a deck section showing a joint splice arranged within the confines of the span portion, web and web flange;

Figs. 10, 11, 12, 13, 14, i5, 16 and 17 show modified forms of internal support;

Fig. 18 is a perspective view partly in section of a floor deck carrying a finished cementitious floor on top of the herein described decking units showing the method of bonding of the floor to the units and the interlock and reinforcements between the units themselves;

Fig. 19 is a sectional view along the line of Fig. 18;

Fig. 20 is a perspective detail of a wedge used beneath a partition to prevent collapse of the tongue and groove;

Fig.2i is a perspective view showing the method of end to end joint of units with a modified form of telescoping joint section;

Fig. 22 is a side elevation of the units of Fig. 21 when joined;

Fig. 23 is a side view of a deck constructed of units of difierent depths;

Fig. 24 is a plan view of a deck of the type shown in Fig. 23;

Fig. 25 is a front elevation of the Fi 24;

Fig. 26 is a plan view partly broken away of a deck construction arranged to incorporate poured cementitious material therewith;

Fig. 27 is a perspective detail showing the method of application of a diaphragm to a building unit to act as a form for poured cementitious material;

Fig. 28 is a. sectional view along the line 28-28 of Fig. 26;

Fig. 29 is a sectional view along the line 29-29 of Fig. 26 showing the cementitious material in place; i

Fig. 30 is a plan view partly broken away showing openings through the spans of adjacent units ready for the pouring of cementitious material thereinto;

Fig. 31 is an assembled perspective view of a unit similar to those shown in Fig. 30 and show ing the manner of applying the diaphragms and bottom plates;

Fig. 32 is an enlarged sectional view along the line 32-32 of Fig. 30 showing the cementitious material in place;

Fig. 33 is a fragmentary perspective of the end of a unit showing the method of using a portion of the span as a diaphragm preliminary to the pouring of cementitious material;

Fig. 34 is a plan view of two units prepared as in Fig. 33 with the cementitious material in place as a wall;

Fig. 35 is a sectional view along the line 35-35 of Fig. 34; r

Fig. 36 is a plan view of a deck construction with a proposed opening marked out thereon;

deck of tween walls, using a hog rod truss;

Fig. 41 is a bottom plan view of the construction of Fig. 40;

Fig. 42 is a perspective view of a dihedral construction, such as a roof peak showing the manner of carrying a unit integrally over the ridge;

Fig. 43 is a diagrammatic end view of a roof construction embodying the arrangement of Fig. 42;

Fig. 44 is a perspective detail of the tie-clip used in Fig. 43;

Fig. 45 is a fragmentary end view. of the support end of a roof construction showing a thrust rod and clip;

Fig. 46 is a perspective detail of the thrust clip of Fig. 45;

Fig. 4'7 is a fragmentary end view of a roof peak using the construction of Fig. 42 showing .one type of finish material applied thereto;

Fig. 48 is a perspective detail of the clips used to hold the shingle battens of Fig. 4'7;

Fig. 49 is a view similar to Fig. 47 showing a modified form of roofing material;

Fig. 50 is a perspective view showing the manner of fastening the finish attaching material between units;

Fig. 51 is a plan view of the construction of Fig. 50 when assembled;

Fig. 52 is a perspective detail showing the manner of attaching an intermediate clip to abeam, the clip to be located between unit sections;

Fig. 53 is a side view of -the construction of Fig. 52;

Fig. 54 is a perspective view of a modified form of attachingclip;

Fig. 55 is a similar view of still another form;

Fig. 56 is a side elevation of a construction embodying theclip of Fig. 55;

Fig. 57 is a diagrammatic end view of an arch roof span showing the use of units of different depths;

Fig. 58 is a fragmentary sectional view along the line 5858 of Fig. 57;

Fig. 59 is a fragmentary sectional view along the line 5959 of Fig. 57;

Fig. 60 is a fragmentary sectional view along the line 60-60 of Fig. 57;

Fig. 61 is a plan view of the roof construction of Fig. 57;

Fig. 62 is a diagrammatic end view of an arch roof span showing a modified construction;

Fig. 63 is a sectional view along the line 6363 of Fig. 62;

Fig; 64 is a view similar to that of Fig. 62 showing still another form of construction;

Fig. 65 is a sectional view along the line 6565 of Fig. 64;

Fig. 66 is a perspective view of a deck using units of this invention in a so-called upside down manner;

Fig. 67 is a partial perspective view showing a form of clip for an upstanding seam;

gether with insulation between the upstanding seams;

Fig. 69 is a fragmentary end view of a roof peak showing the units used in a so-called upside down manner; and

Fig. 70 is a fragmentary perspective view showing an additional manner of fastening the units together.

Referring now with particularity to the figures, Fig. 1 shows perhaps the most preferred form of unit. As shown, it consists of a span portion I having at each of two opposite longitudinal sides thereof webs 2 and 8 containing a tongue and groove I and 5, respectively. Flanges 6 are located at the end portion of each web, which terminate in an angularly bentstiil'ening portion I.

Such imit may advantageously be constructed from sheet metal, the gauge of which may run from, say 8 to 20, although in special locations lighter or heavier gauges may be used. As a matter of fact, for particularly heavy loads, the unit may be madeoi cast metal although ordinarily cold or hot rolled sheet material will be found satisfactory. Where desired, concave corrugations 8 may be formed in the span portion I, in any desired manner in order to lend the required stifiness.

The invention is not to be restricted to any particular dimensions of building unit inasmuch as the particular circumstances under which this element is to be used will determine the requisite size. Ordinarily speaking, sections six inches deep by fifteen inches wide and ten feet long will be found to fit most circumstances, although obviously these dimensions may vary at will.

It is to be noted from an inspection of Fig. 1 that the tongue 4 and groove 5 are complementarily shaped, so that when two such units are erected adjacent each other into a building construction or deck, they may readily engage and interlock, such as in the manner shown in Fig. 23. Under such circumstances, the interlocked webs, together with their adjacent flanges and span portions form I-beams which constitute an important feature of the present construction. This will be readily appreciated when it is remembered that due to the fact that an eflective I-beam occurs in such decking along parallel lines and at closely spaced intervals, considerable loads may be can'ied by such decking even though the unit is constructed of a very light gauge material. The stiffening angular end 1 is of particular importance in this consideration in that it lends a strength and resistance to bending considerably in excess of a constructionin which this feature is absent.

This I- beam effect is enhanced by the interlock between units. In this connection, it is to be noted with particular reference to the tongue 4 shown in the enlarged view of Fig. 5 that the configuration thereof is such that it has a restricted neck. Under these circumstances, the slightly enlarged end of the tongue may be forced into corresponding groove 5 and be securely held therein both by reason of the frictional joint between the parts and also because of the shape of the parts.

While it is desirable that each unit carry complementary locking tongues and grooves, yet this is not necessary as an inspection of Fig. 2 will indicate. There each web 2 is shown to carry a groove 5 and the interlock between the parts is constituted by an elongated latch member 9 having oppositely bent doubled portions ll) adapted 'to tightly fit and be held within the grooves 5 when the two units are pushed together. Other modes of interlocking within the purview of the invention will occur to those skilled in the art.

Fig. 4 shows stiffening corrugations ll of the convex variety which are considered to be the full equivalent of those indicated at 8.

In Fig. 5 a modified form of stiffening portion for the flange 6 is shown to consist of a rolled bead l2.

In assembling such units into a building construction, one lengthwise series will ordinarily be erected in an end to end relationship. In order to adequately support the joint therebetween, the

' telescoping member l3, shown in Fig. 6, may be used. It may conform in close detail to the configurationof a unit except that it will be of such a size as to readily fit within the end thereof, such for instance as is shown in Fig. 21. 0bviously, such telescopic member may also contain full webs 2 and 3 with flanges 6 and stiflening portions 1 as shown in Fig. 6 or the flanges and stiffening portions 6 and I may be omitted as in Fig. 21. In the latter case, the tongue 5 and groove 5 engage the corresponding parts in the full unit so as to fit closely thereinto. By moving another full unit in the direction of the arrows shown in Fig. 21, the two units may abut in an end to end relationship with adequate support to the joint between their span portions.

Having erected a single line of units into a deck construction, a second row of units is then installed in an interlocking manner with the first row of units, preferably in a break-joint arrangement so as to distribute any weakness that may occur at the joint. In Fig. 6, the method of erection is indicated, it being assumed that the units A and B are those in the first line. In order to strengthen the longitudinal edge of such units and to distribute load and develop sheer, 9, splice member indicated generally at M is moved in the direction of the arrows so that its groove l5 overlies the tongues 4 on the units A and B. The

splice member H3 is provided with flanges l6 suffi-v ciently far apart so that when the unit C is moved in the direction of its arrows, its flange B and span portion I will lie between the flanges l6 of the splice member much as is shown at the opposite side of Fig. 6. Such a construction is particularly eiTective where light gauges of metal are used and/or where special loads are to be carried.

Fig. 7 illustrates another form of splice plate I] without flanges as these will not always be required. It is used in exactly the same way as the splice member l4 and serves the same purpose. In addition to the function of the splice plate which is to strengthen the joint between units, it provides a slight space or groove between the longitudinally extending webs of rows of units such, for instance, as is indicated at l8 on Fig. 18. This is sometimes desirable in that it permits the attachment to a construction embodying these units of clips and nails which may be inserted or driven thereinto and frictionally held therein. This feature will be more fully described hereinafter.

Referring back to Fig. 6, there is shown at IS a clip having a, configuration similar to the splice plate of Fig. 7 and provided with apertures which may be used to receive rods 2| or the like shown in Fig. 18 where itis desired to overlay the deck with a cementitious finish material. Such a finish or floor is shown at 22 in Fig. 18.

when such clips are not in use. they may be bent down flush with the desk as shown at 28.

The use of a floor finish such as cementitious material of which concrete is a type is advantageous in that it raises the neutral axis of the structure and the overlay forms the top of a 1' so as to put the concrete under compression and the steel combination in tension. Without the concrete, the neutral axis is located approximately on a line with the tongue and groove and, consequently, the metal parts are both in compression and tension, which is not always desirable.

Where sheet finish material is to be overlaid onto a deck, the clip of Fig. 8 may be used, which is similar in all respects to that shown in Fig. 6 except that it is provided with a penetrating point 24.

While in Fig. 6 the splice plate I4 is shown as being inserted between unitsfor strengthening purposes, it need not always be so located. For instance, in Fig. 9 the splice plate II is shown as being inserted within the confines of a unit defined by its span portion I, web 3 and flange B.

In some cases it will be found desirable to strengthen the I-beam effect of the tongued and grooved edges by internal fittings. Such fittings may occur either across a joint and thus serve a double purpose or not, as desired. Fig. 10 shows a splice plate I! such as is used in Fig. 7 for this purpose. In Fig. 11, a similar plate is indicated having, however, a tongue of such a size as will fit within the tongue 4 on that unit.

In Fig. 12, an open box type of support 26 is shown, the mounting of which is self evident, while in Fig. 13 the same support is shown applied to that side of a unit containing a tongue.

Fig. 15 illustrates a modified form of support 21 applied as in Figs. 14 and 16. There the configuration is such that when the main body of the support is flexed against its end 28, a particularly rigid construction results.

On the other hand, the normally strengthening terminal edge I of a flange 6 of a unit may be extended upwardly as at 29 to engage the underpart of the groove 5 and the tongue 4 as shown in Fig. 17. In addition to the function as a support, this construction may be found desirable where the inner surface of the flanges 6 are to be protected from accumulating dust or moisture.

Where a partition, such as shown at 30 in Fig. 18 is'to be erected onto a floor 22, it may be necessary or desirable to more completely support and prevent collapse of the engaging tongue and groove of meshed units therebeneath. This may be done as in Fig. 19 by providing a wedge 3| of any desired material driven into the tongue and/or groove over the supporting beam or the like 32 and beneath partition 30. I

One of the important features of the use of these units in a building construction is their complete flexibility of application to various circumstances. Fig. 23 shows, for instance, a situation in which a low beam 33 and a high beam 34 are supported on a column 35 at different horizontal levels whereas a deck on a single level is to be mounted thereon. Instead of providing separate framing to carry out the supporting .level of beam 34, it only becomes necessary to use a unit such as that shown at D, which is similar in all respects to units A, B and C, ex-

cept that its web 36 is of greater depth than those of units A, B and C, although the tongue and groove therein occur at the same distance below the span l as in the other units. As a con- 

